Replacing Factory Inverter with Pure Sine Wave Inverter

Thank you!! Looks like I’ll need to work out the difference between those two, since they seem very similar. One other interesting bit: they say the max allowable amperage is 30 amps, but the factory inverter has a 60 amp fuse on it.

Also…how?!

If you don’t mind, can you please enlighten me how you found those connectors? What you searched for? Which sites you used? Right now it just feels like magic and I’m not a fan of magic. :P
 
Thank you!! Looks like I’ll need to work out the difference between those two, since they seem very similar. One other interesting bit: they say the max allowable amperage is 30 amps, but the factory inverter has a 60 amp fuse on it.

Also…how?!

If you don’t mind, can you please enlighten me how you found those connectors? What you searched for? Which sites you used? Right now it just feels like magic and I’m not a fan of magic. :p
Not magic... I have some electrical/wiring contacts from a past position and they helped me out!
 
but the factory inverter has a 60 amp fuse on it

I can't explain that one unless the fuse is protecting for transient spikes in current and the the connector is rated for steady state. Much like generators have startup and continuous ratings. That is a total guess on my part, though!
 
Not magic... I have some electrical/wiring contacts from a past position and they helped me out!
Well that's super appreciated, both to you for asking and them for helping. No way I would have found that otherwise!

I can't explain that one unless the fuse is protecting for transient spikes in current and the the connector is rated for steady state. Much like generators have startup and continuous ratings. That is a total guess on my part, though!
Ya that makes sense, and is what I'm leaning towards as well. Going to do some math and see what I can figure out for how much the inverter will draw.
 
Ok, so the only difference between those two is the type of plastic they're made of. Based on the stamping on the factory one, it's PBT so I'll match that with the male end. That means 7282-6458-40 is the correct part.

After some searching around, I found it for sale on Ebay for $14, plus $5 shipping. So $20. Expensive little connector, but I love the fact this enables me to do this really clean.


(Alternative was buying a minimum of 10 of them from a bulk distributor for $50.)

So next steps for myself regarding the gray connector:
  • Figure out the pins. The Yazaki site lists the part number for them, so I just need to find them, or an equivalent, for purchase.
  • Figure out amperages to be sure I'm happy with the safety of things.
  • Order parts!
Next steps for the brown connector:
  • Do a touch more research to see if I can find a male portion that's intended to go to a wire, rather than be soldered to a board.
  • Order the one I can and figure out adapting it to a wire.
Then it's do the conversion!
 
Ok, so the only difference between those two is the type of plastic they're made of. Based on the stamping on the factory one, it's PBT so I'll match that with the male end. That means 7282-6458-40 is the correct part.

After some searching around, I found it for sale on Ebay for $14, plus $5 shipping. So $20. Expensive little connector, but I love the fact this enables me to do this really clean.


(Alternative was buying a minimum of 10 of them from a bulk distributor for $50.)

So next steps for myself regarding the gray connector:
  • Figure out the pins. The Yazaki site lists the part number for them, so I just need to find them, or an equivalent, for purchase.
  • Figure out amperages to be sure I'm happy with the safety of things.
  • Order parts!
Next steps for the brown connector:
  • Do a touch more research to see if I can find a male portion that's intended to go to a wire, rather than be soldered to a board.
  • Order the one I can and figure out adapting it to a wire.
Then it's do the conversion!
If you buy 10, I'll throw down $10 for one.
 
If you buy 10, I'll throw down $10 for one.
Well, if there's enough interest I'll do it. Wouldn't mind having a spare connector for myself in case I somehow mess the first one up. If there's other interest then I can justify doing the bulk purchase and mailing them out.
 
Thank you!! Looks like I’ll need to work out the difference between those two, since they seem very similar. One other interesting bit: they say the max allowable amperage is 30 amps, but the factory inverter has a 60 amp fuse on it.

Also…how?!

If you don’t mind, can you please enlighten me how you found those connectors? What you searched for? Which sites you used? Right now it just feels like magic and I’m not a fan of magic. :p
Fuses are rated to protect the wire not the device.
 
Fuses are rated to protect the wire not the device.
Interesting! Figured it would protect the connector, too, but good to know!
 
I just found these:

In home.
View attachment 37060

F250 Inverter.
View attachment 37061

Welp... Another part to replace.
yikes..I think a square wave output would be better than that garbage for most devices one would want to plug in. I bet all that dwell time at zero voltage really messes with stuff.
Well that's super appreciated, both to you for asking and them for helping. No way I would have found that otherwise!


Ya that makes sense, and is what I'm leaning towards as well. Going to do some math and see what I can figure out for how much the inverter will draw.

A really simple back of envelope calculation would be 400W/12V/0.9_efficiency = 37A

30A on the connector seems a little light to me especially if you are pulling close to max draw continuously...are you sure there's not a heavier duty version? I realize it was hard to find this one but honestly I would keep looking for a heavier rated one.
 
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Interesting! Figured it would protect the connector, too, but good to know!
Connector too. Fuses and circuit breakers are sized to protect wire connectors etc. so that if there is over current or short the fuse blows before any thing down stream heats up enough to catch fire
 
I'm not starting another project until I have everything it takes to finish it completely. I'm still waiting on shit that I ordered for this truck in January. OBA and Air bags still in the box's waiting on Braided Air Line, King OEM W Adjusters waiting on Retainers, ARE Cap install wanting on Bed Slide. Anything new will be some time next year. 🍻 🍻 ..
 
Touching base on this again. I've been mulling this over while Shadowfax has been in the shop and I couldn't do anything anyways and I've figured out my plan.

I'm going to cut off the factory connectors and, on the bare wires from the rest of the truck, attach my own connectors. Then I'll make two new harnesses to plug into those new connectors.

First harness will be the factory connectors. To switch back to the factory inverter, I just attach this harness and plug in the factory inverter.

Second harness will be setup for the replacement inverter in whatever way I choose.

While this doesn't let me return to completely stock (the new connectors will be present), it does greatly simplify the connector situation as I can use connectors that I know are rated for the amperage I'll be encountering. It also avoids the mess of trying to use the factory ones from a parts standpoint.
 
I get the idea as I have been working in the electrical and electronics fields for well over 30 years, from maritime, defense department and aero space. You can have voltage and not current such as data and signals wires.

As for your battery terminals solders are made up of combining metals so that they will melt and flow and are designed for applications. All of your battery terminals are crimped on to the wires. All off the connections in your car are crimped and use a mechanical connection.

How many of your house hold connections are soldered? None
But you can do what you want to. Soldering wires can work it just not the correct way to do it.
On the Apache helicopter, we soldered all the avionics wiring but not the electrical connections. Even the electrical connections in the engines were direct connect and not soldered. I was a sheetmetal and fiberglass mechanic so I always wondered about why that was done that way. Now that makes sense.
 
Looking forward to seeing your eventual solution.

Admittedly, your walkthrough will likely guide my own installation.
Awesome! Well, I will definitely be documenting it thoroughly. :D
 
Touching base on this again. I've been mulling this over while Shadowfax has been in the shop and I couldn't do anything anyways and I've figured out my plan.

I'm going to cut off the factory connectors and, on the bare wires from the rest of the truck, attach my own connectors. Then I'll make two new harnesses to plug into those new connectors.

First harness will be the factory connectors. To switch back to the factory inverter, I just attach this harness and plug in the factory inverter.

Second harness will be setup for the replacement inverter in whatever way I choose.

While this doesn't let me return to completely stock (the new connectors will be present), it does greatly simplify the connector situation as I can use connectors that I know are rated for the amperage I'll be encountering. It also avoids the mess of trying to use the factory ones from a parts standpoint.
I’ve decided to ignore the factory inverter altogether. It’s useless to me on 2 counts- it’s not 240v and it’s not pure sine wave. When I get my accessory battery and dc to dc charger installed, I’ll wire in a pure sine wave inverter and mount them in all in the tray, and add a volt meter and USB charging points
 
On the Apache helicopter, we soldered all the avionics wiring but not the electrical connections. Even the electrical connections in the engines were direct connect and not soldered. I was a sheetmetal and fiberglass mechanic so I always wondered about why that was done that way. Now that makes sense.
One more reason wires are crimped and not soldered is they are less prone to breaking when moved or flexed. A soldered connection can become hard and stiff due to the solder flowing up the wire, causing it to become brittle at the crimp joint. In this situation, it can easily break if flexed or prone to vibration over a period of time. I only use soldered joints in cases where I can't afford a wire to become a high resistance connection due to water penetration such as on a boat. Even then, I use solder sparingly only at the wire protrusion at the ring and shrink wrap the entire exposed wire, or use a closed end crimp. I also use dielectric grease to ward off moisture.
 
I’ve decided to ignore the factory inverter altogether. It’s useless to me on 2 counts- it’s not 240v and it’s not pure sine wave. When I get my accessory battery and dc to dc charger installed, I’ll wire in a pure sine wave inverter and mount them in all in the tray, and add a volt meter and USB charging points
That makes a ton of sense, particularly with the voltage mismatch.

I still want to retain the factory plugs, so that's my motivation for directly replacing it rather than ignoring it.
 
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